FUEL TANK REPLACEMENT 1994 330 Sundancer

[MojoHaiku]

I need to find someone who has experience replacing a starboard fuel tank on a 1994 330 Sundancer.... My tank developed a leak. I had a replacement made by the original supplier to SeaRay... Now the problem is, it appears next to impossible to get the tank out... This is an I/O boat and generator has been removed... Tank partially slid back but not enough clearance.... Do I split the deck? Do I cut into the hull and access the tank from the side ? so far, I have not found anyone who even knows anyone that has done this... I'm pretty desperate for guidance.... Thanks.....

 

[Jimmy Buoy]

I wouldn't be cutting anything until speaking with someone at Sea Ray that is familiar with your boat.

 

[MojoHaiku]

Hey Jim... Unfortunately I did try that... No one at SR was around when it was built... They've never heard of such a thing on that boat... My plan is to try to network my way to the one or two other people alive who have had to tackle this.... Wlll try to get SR to help me with an email or something out to their dealers..... Aside from that, we're flyin blind....

 

[northern]

On my 28 footer the water tank went. The only way to take it out was to cut it up in place. I then put 2 new tanks in that were half the size of the original. Not a method you want to hear after getting a new one built but it might be the only way to get the tank out and new tankage in. If you land up cutting the old one up make sure it is gas free. Steaming it out may be required. Get a gas detector and make sure you have ZERO gas vapour in the tank. Washing with water does not take the gas vapours out.
I used two tall skiny tanks and plumbed them together.

 

[MojoHaiku]

Thanks Northern.... Will definitely add that to my list of options... Man, on my 330, water tank replacement looks super easy...! My mechanic tried to lift the deck but could only get it up about an inch and a half up off the hull... If I can figure out a couple of other points holding the deck down, and relieve those, maybe I can lift it a couple of more inches and that just might be enough.... This is such a shame... The boat is in excellent condition... Only 400 hrs on it.... But man, is this one costing me... Thanks for your help....

 

[Jimmy Buoy]

Airplanes often have bladders placed into the top of the tank. If the tank is not able to be removed without either cutting it or the boat, it might be an option...

A quick Google search reveals quite a few bladder manufacturers out there. Now if you could order one that would fit the interior size of your tank that might work. Here's the link.

http://atlinc.com/marine.html

 

[fwebster]

You guys do know that Sea Ray has dealers who are supposed to be able to handle this type of repair don't you?

As far a cutting the boat, that is precisely how engines are removed from multi-million $ yachts. An access door is cut in the hull, the door set aside and the engine pulled out sideways. When the engine is back in place the door is fiberglassed back in place and the gelcoat is repaired or the hull is repainted. On a Sea Ray The hull side from the rubrail down to the chine has no major structural components in it, so removing a trap door to access tanks engines, etc. would be a relatively easy sawz-all/fiberglass repair job. I don't know the 330DA that well and I am not advocating cutting the side out of the boat to get to the fuel tank, only that removing something like the cockpit floor or hull side shouldn't be that difficult for someone experienced in such repairs.

 

[MojoHaiku]

Thanks guys... I am really hoping to find someone who has dealt with this on the 330.... Going in one direction and having to back up and then head in another will end up costing (wasting) thousands... Calls to the local SR dealer as well as SR corporate have only yielded "never heard of a leaker on a '94 330 and there's no procedure for that" responses... There has to be someone out there that has blazed this trail.... When this is over with, I will definitely publish my experience for others.... Since I had the boat out of the water I went ahead and had bottom painted and full service on the out drives... Those things plus the grand I spent on the custom built tank has me in well over $6000, and my new tank is still sitting on a pallet.... Oh well... Trying to stay positive.... Thanks again....

 

[northern]

Looks like a nice tank.
Is it the height or length that stops it from going in.
If height SeaRays are made in 2 halfs like a shoe box. They are screwed together with 1" long screws and the two halfs are cyliconed together. Lot of work to take it apart. I resealed mine once took 16 hours.
If length you could ask what they would charge to cut the tank in half and put fittings on it so you could make it one tank again.

 

[MojoHaiku]

Unfortunately, height is the problem... If I could get the deck up off the hull a few inches, I may be able to do the R and R.....

 

[MojoHaiku]

Haven't been on the forum in a while and just remembered that I didn't circle back on this and report on my results... Starboard tank leaked. Transferred fuel to port tank. Hauled out boat. Removed stbd engine and generator. Ordered a new tank from the original manufacturer ($1000). My mechanic had to cut out the old tank. New tank wouldn't slide right in or course, so he separated the deck from the hull, but could only lift it about 1-1/2" before all of the creaking and popping signaled a great deal more disassembly up inside the boat would be required to go any further... Had to cut out piece of the deck, right behind the ice maker / sink, about 1.5' X 10" or so... Tried to slide the new tan in - still no dice. Cut 11" off of my $1000 tank and it went in... Put everything back together and had fiberglass repaired... While it was out, had bottom painted and out drives serviced... So, I'm $12,000 poorer and my stbd tank has 15 gallons less capacity than my port...

BUT, I am back to enjoying my beloved Sundancer now that the nightmare is over...

 

[SC Sundancer]

I have the same boat. I removed the starboard tank through the cabin. I cut out the side wall and about 8 inches of the firewall and removed it all in one piece. The tank then came out into the cabin and went out the door. Once the the repair was made i put it back in place and fiberglassed it all back in. I think i posted videos to youtube during this time. I think it is The330sundancer.